A long-life hot cathode fluorescent lamp can include a pair of parallel lead wires that can be arranged at each end of a tube. A coiled filament can be connected at its opposite end portions to the lead wires. The coiled filament can have two long pitched regions in which a coil pitch is longer than regions outside of the long pitched regions. emitter can be located in a region defined between the two long pitched regions. Shape characteristics and intensive current flow obtained by the presence of the long pitched regions can form the origins of discharge near the boundaries between long and short pitched regions. Accordingly, stable discharge can be achieved with the origins of discharge located at ends of the emitter. As a result, the hot cathode fluorescent lamp is allowed to have a long life and stable light emission characteristics.
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20. An electrode for a fluorescent lamp, comprising:
a glass member of a fixed shape;
a pair of substantially parallel lead wires adjacent the glass member; and
a coiled filament having opposite end portions which are connected to the substantially parallel lead wires, respectively, and an emitter located on the coiled filament, wherein the coiled filament has two long pitched regions in which a coil pitch of the coiled filament in the two long pitched regions is greater than every coil pitch of the coiled filament located in regions outside of the two long pitched regions, a continuous region of the coiled filament located between the two long pitched regions includes the emitter, and all regions of the coiled filament other than the region between the two long pitched regions does not include the emitter.
1. A hot cathode fluorescent lamp, comprising:
a tube including opposite ends of the tube;
a pair of substantially parallel lead wires arranged at each end of the tube;
a coiled filament having opposite end portions which are connected to the substantially parallel lead wires, respectively; and
an emitter located on the coiled filament, wherein the coiled filament has two long pitched regions in which a coil pitch of the coiled filament in the two long pitched regions is greater than the coil pitch of the coiled filament located in regions outside of the two long pitched regions, a continuous region of the coiled filament located between the two long pitched regions includes the emitter, and an entirety of the coiled filament other than the continuous region between the two long pitched regions does not include the emitter.
2. The hot cathode fluorescent lamp according to
the coiled filament has a void at each of the coiled filament opposite end portions;
a tip portion of each of the pair of the lead wires is inserted a predetermined length into a respective void at each of the coiled filament opposite end portions, so that the coiled filament and the lead wires are fixed together; and
part of the coiled filament spaced from the lead wires is bent.
3. The hot cathode fluorescent lamp according to
4. The hot cathode fluorescent lamp according to
5. The hot cathode fluorescent lamp according to
6. The hot cathode fluorescent lamp according to
7. The hot cathode fluorescent lamp according to
8. The hot cathode fluorescent lamp according to
9. The hot cathode fluorescent lamp according to
10. The hot cathode fluorescent lamp according to
11. The hot cathode fluorescent lamp according to
12. The hot cathode fluorescent lamp according to
13. The hot cathode fluorescent lamp according to
14. The hot cathode fluorescent lamp according to
15. The hot cathode fluorescent lamp according to
16. The hot cathode fluorescent lamp according to
17. The hot cathode fluorescent lamp according to
18. The hot cathode fluorescent lamp according to
19. The hot cathode fluorescent lamp according to
21. The electrode for a fluorescent lamp according to
the coiled filament has a void at each of the coiled filament opposite end portions;
a tip portion of each of the pair of the lead wires is located a predetermined length into a respective void at each of the coiled filament opposite end portions, so that the coiled filament and the lead wires are fixed together; and
part of the coiled filament spaced from the lead wires is bent.
22. The electrode for a fluorescent lamp according to
23. The electrode for a fluorescent lamp according to
24. The electrode for a fluorescent lamp according to
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This application claims the priority benefit under 35 U.S.C. §119 of Japanese Patent Application No. 2009-071542 filed on Mar. 24, 2009, which is hereby incorporated in its entirety by reference.
1. Technical Field
The presently disclosed subject matter relates to a long-life hot cathode fluorescent lamp with stable light emission characteristics.
2. Related Art
Cold cathode fluorescent lamps have widely been used as light sources of backlight units for use in large-sized liquid crystal televisions, for example. In light of the recent importance associated with energy savings, it has been suggested that hot cathode fluorescent lamps, superior in light emission efficiency to cold cathode fluorescent lamps, be used as light sources of backlight units.
Light sources of backlight units for liquid crystal display devices have been required to be long life, and small in diameter. These two requirements should be satisfied when hot cathode fluorescent lamps are to be used as light sources of backlight units for liquid crystal display devices.
The lifetime of a hot cathode fluorescent lamp is shortened with degradation of its fluorescent substance, a reduction of filling gas, and other characteristics. The most important determining factor of lifetime is the amount of electron emission material (emitter) that is applied to a coil filament (hereinafter simply referred to as a coil) serving as an electrode. So, a desirable structure of the electrode of a hot cathode fluorescent lamp has been one in which the amount of emitter can be applied can be increased. However, there is a competing interest in that an electrode should also be small in size to allow a small diameter for a fluorescent lamp. Thus, the electrode should be of a structure that allows a greater amount of emitter to be applied in smaller space.
A coil can generally serve as an electrode after being attached to a pair of lead wires and then fixed therebetween. Suppose a case where a coil is incorporated in a hot cathode fluorescent lamp of a large diameter (what is called a fluorescent tube) generally applied for lighting purposes, such as the case disclosed in figure three of Japanese Patent Application Laid-Open No. Hei 6-295704. In this case, the hot cathode fluorescent lamp can have a coil in which the axis of the coil extends in a direction perpendicular to a direction in which the axis of the lead wires extends, and opposite ends of the coil are supported by the tips of the lead wires. Generally, the coil and the lead wires can be fixed by bending and swaging the tips of the lead wires so that the coil can be held in place.
Japanese Patent Application Laid-Open No. 2004-303620 discloses an example of a hot cathode fluorescent lamp of a small diameter. This hot cathode fluorescent lamp employs a structure where the axis of a coil with only one turn extends in a direction perpendicular to a direction in which the axis of a lead wire extends.
Here, it is assumed that a fluorescent lamp with a glass tube of a small diameter employs a structure as disclosed in Japanese Patent Application Laid-Open Nos. Hei 6-295704 and 2004-303620 in which the respective axes of a coil and a lead wire extend in directions perpendicular to each other. In this case, the opposite end portions of the coil may project outward of the lead wire (in the direction of a tube diameter), so that the coil may disadvantageously contact the inner wall of the glass tube.
An electrode structure responsive to reduction of the diameter of a fluorescent lamp and which provides improved means for fixing of a coil and lead wires has been suggested in figure one of Japanese Patent Application Laid-Open No. Hei 6-295704, for example. In this electrode structure, the coil is bent into a U shape, and is then fixed to the lead wires so that the axis of the coil at its opposite end portions extends in the same direction as the axis of the lead wires. Then, the coil is fixed by welding to the lead wires.
Japanese Patent Application Laid-Open No. 2005-235749 discloses a coil formed into a helical shape. Accordingly, in this case, the axis of a filament of the coil at its end portion extends in the same direction as the axis of a lead wire. Thus, the end portion of the coil can be fixed to the lead wire with their respective axes extending in the same direction. Also in this case, the coil and the lead wire are fixed by welding. While not disclosing a concrete way of welding, there is disclosed process steps including welding with the core of the coil remaining as it is, and subsequent dissolving of the core.
When employed in a fluorescent lamp with a glass tube of a small diameter, the above-described lamp structure where the axis of a coil extends in a direction perpendicular to a direction in which the axis of a lead wire extends may cause problems as described below.
In more detail, in the structure of a common hot cathode fluorescent lamp disclosed in Japanese Patent Application Laid-Open No. Hei 6-295704, an end portion of a coil can project outward of a lead wire, so that the end portion of the coil may contact the inner wall of a glass tube (a coil touch is generated). Generation of the coil touch can transfer heat of the coil to the inner wall of the glass tube while the lamp lights up. This melts the glass tube by heating, thereby causing possible leakage, deformation, etc. In a process for activating a material of the emitter applied to the coil by using a coil current to make the material serve as emitter, generation of the coil touch also transfers heat of the coil to the inner wall of the glass tube contacting the coil. In this case, the heat is diffused throughout the glass tube, and then escapes. Accordingly, the emitter cannot be heated and activated sufficiently, thereby shortening the lifetime of the emitter.
Furthermore, using a coil with only one turn as disclosed in Japanese Patent Application Laid-Open No. 2004-303620 results in reduction of coil length. This reduces the amount of emitter that can be applied to the coil, so that attempts to provide a long-life fluorescent lamp are frustrated.
Considered next is a structure where a coil is bent into a U shape and is then fixed to a lead wire as disclosed in Japanese Patent Application Laid-Open No. Hei 6-295704. In this device, when emitter is to be applied in sufficient abundance, a boundary between a region to which emitter is applied and a region to which no emitter is applied is defined in a linear portion near the lead wire. This makes it impossible to define the origin of discharge, resulting in a possibly unstable stage of discharge. Also, in this device, an end portion of the coil and the lead wire are closely aligned along some length, and partially welded by a metal bump at one point. Accordingly, a portion of the coil from its welded point to its end remains unfixed and is a redundant portion that does not contribute to discharge. This redundant portion may disadvantageously be bent to project toward the wall of a glass tube, so that a coil touch may be generated.
Furthermore, the coil is arranged along the lead wire, and is welded to the lead wire at a contact point. This may cause the coil to vibrate easily. Furthermore, the coil, if fixed in a stressed condition to the lead wire, may be deformed while a lamp lights up. Vibration or deformation of the coil that occur while the lamp lights up may make it impossible to achieve desirable characteristics, or may cause a failure that hinders the lamp from lighting up or shortens the lifetime of the lamp.
Also, the coil may be thermally shocked depending on a welding condition, by which tungsten being the principal component of the coil may become brittle. This may cause a failure leading to the wearing out or breakdown of the coil while the lamp in its finished state lights up.
Regarding the helical coil disclosed in Japanese Patent Application Laid-Open No. 2005-235749, a straight filament at an end portion of the coil and the linear lead wire are connected to each other. In order to do so, a connection reinforcing member called a heat tab is used. In this case, the size of the connection reinforcing member may hinder diameter reduction of a glass tube.
The presently disclosed subject matter was devised in view of these and other characteristics, features, problems and in association with the conventional art. According to an aspect of the presently disclosed subject matter, there is provided a long-life hot cathode fluorescent lamp with stable light emission characteristics.
According to another aspect of the disclosed subject matter, a hot cathode fluorescent lamp can include: a tube configured to be sealed at its opposite ends; a pair of parallel lead wires arranged at each end of the tube; a coiled filament having opposite end portions which are connected to the parallel lead wires, respectively; and emitter held on the coiled filament, wherein the coiled filament has two long pitched regions in which a coil pitch is longer than that in their surrounding regions, and a region defined between the two long pitched regions contains the emitter. Shape characteristics and intensive current flow obtained by the presence of the long pitched regions can form the origins of discharge near the boundaries between long and short pitched regions. Accordingly, stable discharge can be achieved with the origins of discharge placed at ends of the emitter. As a result, the hot cathode fluorescent lamp is allowed to have a long life and stable light emission characteristics.
As an example, the coiled filament can be configured such that the tip portions of the pair of the lead wires are inserted a predetermined length into voids of the coil filament at its opposite end portions, respectively, so that the coiled filament and the lead wires are fixed together. The coiled filament can also be configured such that part of the coiled filament that does not hold the lead wires therein is bent. This can prevent a coil touch caused by the contact of the coiled filament with the tube wall, and allows the lead wires to be well spaced from each other. As a result, a greater amount of emitter can be applied.
The coiled filament may be a multiple winding coil, for example. In this case, antivibration performance can be improved in the long pitched regions. The voids of the coil filament at its opposite end portions may be formed by the multiple winding coil.
The two long pitched regions each can extend a predetermined length from the tip of each of the lead wires so that the emitter can be applied to a region of a greater length. The long pitched regions can have a length in a range of not less than 2.5 times and not more than 7 times the length of the region defined between the two long pitched regions.
The emitter can cover the region in its entirety defined between the two long pitched regions of the coiled filament. This is because it allows boundaries between the long and short pitched regions in which a current flows intensively to coincide with the ends of the emitter, and increases the amount of emitter.
Another aspect of the presently disclosed subject matter is the ability to provide an electrode for a fluorescent lamp. More specifically, the electrode can be used in a fluorescent lamp and can include: a glass member of a fixed shape; a pair of parallel lead wires held by the glass member; and a coiled filament having opposite end portions which are connected to the parallel lead wires, respectively. The coiled filament has two long pitched regions in which a coil pitch is longer than that in their surrounding regions.
As an example, the coiled filament can be configured such that the tip portions of the pair of lead wires are inserted a predetermined length into voids of the coil filament at its opposite end portions, so that the coiled filament and the lead wires are fixed together. The coiled filament can also be configured such that part of the coiled filament that does not hold the lead wires therein is bent.
The coiled filament may be a multiple winding coil, for example. The voids of the coil filament at its opposite end portions may be formed by the multiple winding coil.
These and other characteristics, features, and advantages of the presently disclosed subject matter will become clear from the following description with reference to the accompanying drawings, wherein:
An exemplary embodiment of a hot cathode fluorescent lamp made in accordance with principles of the presently disclosed subject matter will be described below.
As shown in
By way of example, the coil filament 20 can be a double winding coil having a filament diameter of about 4 MG (36.5 μm), a primary coil diameter of about 0.153 mm, and a secondary coil diameter of about 0.63 mm.
It should be noted that in the present description the axial direction of the coil may mean the extending direction of the secondary winding (in the vertical direction of the filament coil 20 shown in
The coil filament 20 bent into a U shape can have two long pitched regions 21 in predetermined positions where the secondary winding is long pitched. As shown in
A short pitched region defined between the two long pitched regions 21 can be coated with emitter 22.
As shown in
Provided that the coil pitch of the secondary winding in the short pitched region has a ratio of 1:1 or 100%, the coil pitch in the long pitched regions 21 may have a ratio in a range of not less than 2.5:1 or 250% and not more than 7:1 or 700%, and more preferably, in a region of not less than 2.5:1 or 250% and not more than 4:1 or 400%. A still more preferable coil pitch may be about 3:1 or 300%. The actual length of the secondary winding in the long pitched regions 21 may beneficially be about 0.5 to 1.5 mm. This is because, the long pitched regions 21, when they are too short, transfer heat from the emitter 22 to the lead wires 12, so that a temperature decrease of the coil filament 20 and emitter 22 may occur. When the long pitched regions 21 are too short in length, it may be difficult to apply the emitter 22 only to a region between the long pitched regions 21 at the time of manufacture. Conversely, the long pitched regions 21, when they are too long, degrade anti-vibration performance.
The pitch can differ largely between the long pitched regions 21 and the short pitched region. For example, the coil filament 20 can have one-half a turn of wire in the long pitched regions 21. This is because when there is an insufficient difference in pitch between the long pitched regions 21 and the short pitched region it can be difficult to define the origin of discharge of the emitter 22. The coil filament 20 is not necessarily required to have one-half a turn of wire in the long pitched regions 21, but may have a greater number of turns of wire such as one turn, or one and a half turns, etc.
As discussed, the long pitched regions 21 can be formed by stretching out part of the secondary winding of the double winding coil to reduce the number of turns of wire to a fixed number. This means that, in the long pitched regions 21, the filament coil 20 is not a single wire of tungsten, but is in the form of a structure formed by winding a single coil (primary winding) very loosely. Thus, stress applied as a result of vibrational shock to the fulcrum of vibration can be diffused throughout the long pitched regions 21. Further, the primary winding in the long pitched regions 21 can serve to disperse vibration. Accordingly, the coil filament 20 can provide higher antivibration performance than typical coil filament structures. The coil filament 20 can also prevent a failure, such as a breakdown of a filament or drop-off of emitter material that may be generated during vibration.
An exemplary embodiment of a process of forming a hot cathode fluorescent lamp will be described next.
First, a tungsten filament can be wound into a coil (primary winding) with a certain pitch, and the coil can further be wound (secondary winding) with another certain pitch. A resultant double winding coil can be bent into a U shape. Then, the secondary winding can be stretched out in predetermined positions to a predetermined length to form the long pitched regions 21. At this time, the double winding coil can be placed into a die prepared in advance in such a way that the entire shape of the double winding coil conforms to the die, so that the second winding is stretched out. This allows the long pitched regions 21 of the predetermined length to be formed precisely in the predetermined positions. Then, the coil filament 20 with a structure shown in
Next, a stem can be formed by using a known process. The stem may include a pair of lead wires 12, and a sealing glass member of a certain shape made of glass beads or the like through which the lead wires 12 penetrate. Next, as shown in
The slurry 41 can be made by diffusing powder of a high-melting point metal such as molybdenum or tungsten into an organic solvent or the like, and by processing the mixture into a form of slurry or paste. The powder of the high-melting point metal can have a particle diameter of about 5 to 20 μm, and can beneficially be about 10 μm.
Next, as shown in
The coil filament 20 can be fixed to the lead wires 12, and the stem (e.g., the pair of lead wires 12, and a sealing glass member of a certain shape made of glass beads or the like through which the lead wires 12 penetrate) when coated with the emitter 22 (hereinafter referred to as a mount) can be inserted into a glass tube 10 of a certain diameter through one end thereof. Then, the sealing glass member made of glass beads or the like and the glass tube 10 can be melted to seal the glass tube 10.
Next, another mount can be inserted into the glass tube 10 through the other end thereof. Then, an exhaust pipe can be connected to the glass tube 10, if necessary, and a mercury source can be inserted into the glass tube 10 or the exhaust pipe. Air inside the tube 10 can be thereafter sucked out to create a vacuum. Then, with the glass tube 10 in this condition, a current can be supplied to the coil filaments 20, and the emitter 22 can be activated by heating. At this time, the lead wires 12 can be located in the end portions of the coil filaments 20, so that the end portions of the coil filaments 20 do not contact the wall of the glass tube 10. This prevents heat transfer to the wall of the glass tube 10, and allows the emitter 22 to be activated by sufficient heating. Further, the region coated with the emitter 22 and each of the lead wires 12 can be spaced apart by a length of the long pitched region 21. Thus, heat of the region coated with the emitter 22 resists being transferred to the lead wires 12, so that the emitter 22 can be activated by sufficient heating.
After activation of the emitter 22, a predetermined discharge gas can be filled inside the space, and the glass tube 10 or the exhaust pipe can be sealed. Thereafter mercury can be released from the mercury source by using a known process. Then, the glass member made of glass beads or the like of the mount and the glass tube 10 can be joined together to seal the glass tube 10.
Next, in order to stabilize the characteristics of the lamp in an initial lighting period, a current is supplied to the coil filaments 20 for a predetermined period of time so that the emitter 22 will age. By following the processes described so far, the hot cathode fluorescent lamp of the present exemplary embodiment can be completed.
A fixed current can be applied to the coil filaments 20 in order to turn the hot cathode fluorescent lamp on. As shown in the photograph of
The origins of discharge placed in fixed positions (boundaries between the long and short pitches) makes it possible to shorten time of processing (aging) required for stabilization of the characteristics of the lamp in an initial lighting period.
In the embodiment of
Furthermore, the absence of fear of a coil touch allows the emitter 22 to be heated sufficiently, while avoiding a problem of leakage to occur by a crack in the glass tube 10 due to a coil touch.
The presence of the long pitched regions 21 in the coil filaments 20 can prevent the solution that contains the material of the emitter 22 from adhering to the lead wires 12 during the process of applying the emitter 22. This facilitates definition of a region to be coated with the emitter 22, allowing the emitter 22 to be applied in a stable amount. Thus, variation in lifetime of the hot cathode fluorescent lamps can be prevented.
Further, the presence of the long pitched regions 21 in the coil filaments 20 formed by stretching out the double winding coil advantageously causes stress applied as a result of vibrational shock to a fulcrum point of vibration to be diffused throughout the long pitched regions 21. Also, the long pitched regions 21 can be formed by stretching out the secondary winding of the double winding coil. This means that, in each of the long pitched regions 21, the filament coil 20 is not a single wire, so the primary winding in the long pitched regions 21 can also serve to disperse vibration. Thus, the coil filaments 20 can provide higher antivibration performance than a coil filament of generally known structures, thereby preventing a failure, such as a breakdown of a filament or drop-off of emitter material, to be generated during vibration.
Laser welding using a slurry containing a high-melting point metal such as molybdenum or tungsten can be used for welding the coil filaments 20 and the lead wires 12. Thus, a failure of the coil filaments 20 such as deformation, embrittlement or breakdown by welding is unlikely, resulting in low probability of occurrence of problems, such as unexpectedly short lifetime or unstable discharge.
It will be apparent to those skilled in the art that various modifications and variations can be made in the presently disclosed subject matter without departing from the spirit or scope of the presently disclosed subject matter. Thus, it is intended that the presently disclosed subject matter cover the modifications and variations of the presently disclosed subject matter provided they come within the scope of the appended claims and their equivalents. All related art references described above are hereby incorporated in their entirety by reference.
Matsuda, Junji, Yoshida, Mitsunari
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Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
Mar 23 2010 | Stanley Electric Co., Ltd. | (assignment on the face of the patent) | / | |||
Apr 12 2010 | MATSUDA, JUNJI | STANLEY ELECTRIC CO , LTD | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 024353 | /0650 | |
Apr 20 2010 | YOSHIDA, MITSUNARI | STANLEY ELECTRIC CO , LTD | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 024353 | /0650 |
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